Fragile article cartons



Dec. 24, 1963 G. E. BYASSEE FRAGILE ARTICLE CARTONS Filed Jan. 7, 1963 FIGI FIG} INVENTOR.

GUY E. BYASSEE A TTORNEY United States Patent 3,115,290 FRAGHJE ARTICLE CARTONS Guy E. Byassee, 802 Huntington Road, Louisville, Ky. Filed Jan. 7, 1963, Ser. No. 249,646 3 Claims. (Cl. 229-39) This invention relates to a collapsible carton for fragile articles. More particularly this invention relates to a carton formed from a single blank, delineated with score lines, cut score lines, and two crease lines, the resultant blank then being formed into a collapsible carton by automatic machine known in the industry.

The collapsible carton is of the type which is then used by packagers in its collapsed state, the collapsible carton being fed into an automatic packaging machine where it is automatically opened into an erected condition for automatic loading of electric tubes, light bulbs, and the like. These loading machines operate at high speeds of about 150 to 200 tubes per minute. Therefore, it will be recognized that the collapsible carton must be formed and glued in a manner which will insure its automatic erection without failure. This has presented a serious problem to the industry.

This invention provides a satisfactory carton for automatic loading and accomplishes this result with an important reduction in the material required for the carton. The carton involves the usual four outer panels which may be viewed as being wound in a predetermined clockwise direction followed by a first lap panel extending in the clockwise direction which is adhered to the inner face of the first panel adjacent its free edge. At this point, the wind is reversed and may be viewed as counterclockwise with the first cushion panel extending across the carton in an erected condition followed by a second lap panel extending upwardly and a second cushion panel extending across the carton and having an end lap panel which extends toward but not to the first cushion panel. This reversal of wind of the blank places the relatively more expensive liner paper used for the outer surface of the carton at the opposed inner faces of the two cushion panels and the lap panels adjacent thereto. fashion, the relatively expensive smooth outer liner used for printed matter on the outside of the carton provides a smooth product engaging surface within the cell of the box to facilitate the loading operation.

The reverse wind feature also eliminates a panel required in cartons made with a continuous wind in the same direction. Furthermore, the reversed wind of the instant invention produces a carton in collapsed condition which has an even number of layers of material at each side of the longitudinal center line of the collapsed carton, this being important in the gluing operation as it produces a balanced arrangement of panels. This balanced number and thickness of layers on either side of the collapsed carton is particularly important in the packaging machine hopper where the cartons have a tendency to lay more flat as opposed to cartons of the prior art having an uneven number of panels on either side.

Of particular importance is the provision of a crease line at the longitudinal center line of the cushion panels, the cushion panels being of substantially the same transverse span or length between the outer side walls of the carton in erected condition. It will be understood that the carton dimensions will vary somewhat due to manufacturing tolerances as well as atmospheric conditions. The instant invention is directed to cushion panels of the same transverse span as the transverse span between the outer wall panels. The crease lines have a substantial width, and their inlet ends serve primarily as a funnel to guide the tube centrally into the erected carton. These crease lines also serve to provide width elongation for a cushion panel which may, through manufacturing tol- In this erances or atmospheric conditions, be slightly shorter than the desired span. If the cushion panel is slightly oversized, i.e. longer than the desired span, the crease line builds in a tendency to spring the panel outwardly and thereby insures the presentation of outwardly flexed cushion panels to an incoming tube rather than inwardly directed cushion panels which might cause a stoppage of the packaging machine due to non-entry of the tube.

The reverse wind of the instant carton also provides a carton in collapsed condition which has a tendency to remain in a flattened state since the inner cell is formed with only one fold of degrees, the other folds of the inner cell being in flat condition. This feature also facilitates the gluing operation and more particularly facilitates the erection operation insuring a more foolproof final package for use in automatic machinery.

The novel features of the present invention are set forth in the appended claims; additional objects and advantages will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a plan view of one form of carton blank embodying the invention;

FIG. 2 is a view showing the carton in collapsed condition during the gluing operation, the carton being shown in slightly erected condition for clarity;

FIG. 3 is a transverse cross section in perspective through the carton showning the carton in erected condition; and

FIG. 4 is an enlarged view showing the crease line .cushiori panel.

As shown in FIGS 1 and 3, the carton is formed from a single blank having four successive outer panels 10-43 which form the outer wall of the carton and five succes sive inner panels 14-18. These nine successive hingedly connected panels are delineated by score lines except between the first lap panel 14 and bottom cushion panel 15 where a cut score line is used; also, a cut score line exists between the top cushion panel 17 and the second lap panel 16. The placement of these out score lines has been selected after tests of this carton to facilitate its erection by automatic machinery. It will be noted in FIG. 2 that the first cut score line 26 and the second cut score line 27 are located respectively along the opposite outer panels 10 and 12 of the carton to facilitate breaking of these joints on erection. Suitable closure flaps 21 are provided at each end of the carton in normal fashion. Cuts on the ends of the bottom and top cushion panels 15 and 17 impart flexibility to these panels.

Glue panels are provided at pre-determined locations; namely, on the outer surface of the first lap panel 14 and the inner surfaces of second lap panel 16 and end lap panel 18, the inner surface glue areas 39 and 40 being shown in FIG. 1 by dotted rectangles.

In the production of this carton, the blank is cut from paper board stock, and calculations have shown that the reverse wind concept of the carton results in the elimination of a panel width which, in certain comparisons with other cartons now on the market, results in a saving of paper board stock material of 8.3 percent in one instance and 13.2 percent in another instance. This factor is considered of significant importance since the paper board stock represents a significant portion of the actual selling price of the carton; in some instances the raw material, namely, the paper board stock, represents up to 50 percent of the final selling price. A saving, therefore, of the raw material is a most significant item. The instant invention accomplishes this saving without sacrifice of the protective cushioning of fragile articles in a single blank carton which must be produced in an automatic packaging machine.

The blank, when cut, is then folded and glued in automatic carton forming machinery under known techniques. In the instant case, it will be recognized from FIGS. 2 and 3 that the blank is folded in a clockwise manner to form the outer walls with the first lap panel 14 extending upwardly inside the first Wall panel 141 and adhered to the inner face of the panel adjacent its free edge. At this point, the remaining successive panels are reversely wound in a counterclockwise direction to form the inner cell which is represented in FIG. 3 as comprising the inwardly facing surfaces of cushion panel 15, second lap panel 16 which adheres to the longitudinal central portion of the third panel 12, cushion panel 17, and the end panel 18 which adheres to the longitudinal central portion of the first panel 111. As seen in FIG. 2, the resultant collapsed carton, shown in slightly erected position for clarity, presents four layers on each side of the longitudinal median line 33 and thereby offers the same thickness to the contact glue rollers 30. It will also be noticed that only score line 27 involves a 180 fold, whereas the other score lines 26, 28, and 29 of the inner cell are positioned between panels 15, 16, 17, and 18 which extend in a flat condition.

The outer walls of the carton carry identifying printed matter regarding the article carried within. This identifying matter is printed with multi-color inks on an outer liner 34 of high quality paper; this liner S4 is applied over one surface of the basic paper board stock 36. The paper liner has a smooth surface and through the reverse wind concept of the instant invention provides the protective contacting surface 37 in the inner cell. This smooth surface facilitates the insertion of the tube.

The transverse span of cushion panels 15 and 17 is substantially equal to the span between the outer panels and 12. Due to manufacturing tolerances and atmospheric conditions, the actual transverse span of the cushion panels may vary. The instant invention provides a groove or crease line 35 of substantial predetermined width of i to & of an inch which is formed in the opposed inner faces of the cushion panels and 17. The crease line serves to widen a narrow panel and to build in an outward springing or flexing stress in an oversize panel. The crease line in effect is a safety factor which is of substantial size to compensate for dimensional variation to outwardly flex o ersize cushion panels and to define with each other a tunneling device for guiding tubes in the center portion of the cell on injection by the automatic loading machine.

While particular embodiments of the present invention have been shown and described, it is apparent that changes and modifications may be made without departing from this invention in its broader aspects. Therefore, the aim b of the appended claims is to cover all such changes and modifications as fall Within the true spirit and scope of this invention.

determined direction to form the outer wall of the carton with the first lap panel adhered to the inner face of the first panel adjacent its free edge,

the remaining four successive panels being reversely 15 wound and including a first cushion panel, a second lap panel, a second cushion panel, and an end lap panel,

said second lap panel being adhered to the longitudinal central portion of said third panel and said end lap panel being adhered to the longitudinal central portion of said first panel,

said cushion panels having a transverse span substantially equal to the span between said first and third panels when the carton is in erected condition,

said blank having a smooth outer liner which provides a smooth product engaging surface in the inner cell formed by said remaining four panels,

said cushion panels having central longitudinal crease lines of predetermined width forming grooves in the opposed inner faces of the cushion panels for insuring outward flexing of slightly oversize cushion panels and width elongation of slightly undersize cushion panels, the inlet ends of said crease lines forming a funnel for centrally guiding a product into the carton.

2. A collapsible single blank carton according to claim 1 and wherein said crease lines have a width of A to of an inch.

3. A collapsible single blank carton according to 40 claim 2 and wherein the hinge connections are score lines except for a cut score line between the first lap panel and the first cushion panel and a cut score line between the second lap panel and the second cushion panel.

References Cited in the file of this patent UNITED STATES PATENTS 2,732,123 Bolding Ian. 24, 1956 2,783,692 Bolding Mar. 5, 1957 3,029,998 Taylor Apr. 17, 1962 

1. A COLLAPSIBLE SINGLE BLANK CARTON OF RECTANGULAR CROSS SECTION HAVING NINE LONGITUDINALLY EXTENDING HINGEDLY INTERCONNECTED PANELS, SAID NINE PANELS INCLUDING SUCCESSIVELY FIRST, SECOND, THIRD, FOURTH AND FIRST LAP PANELS WOUND IN A PREDETERMINED DIRECTION TO FORM THE OUTER WALL OF THE CARTON WITH THE FIRST LAP PANEL ADHERED TO THE INNER FACE OF THE FIRST PANEL ADJACENT ITS FREE EDGE, THE REMAINING FOUR SUCCESSIVE PANELS BEING REVERSELY WOUND AND INCLUDING A FIRST CUSHION PANEL, A SECOND LAP PANEL, A SECOND CUSHION PANEL, AND AN END LAP PANEL, SAID SECOND LAP PANEL BEING ADHERED TO THE LONGITUDINAL CENTRAL PORTION OF SAID THIRD PANEL AND SAID END LAP PANEL BEING ADHERED TO THE LONGITUDINAL CENTRAL PORTION OF SAID FIRST PANEL, SAID CUSHION PANELS HAVING A TRANSVERSE SPAN SUBSTANTIALLY EQUAL TO THE SPAN BETWEEN SAID FIRST AND THIRD PANELS WHEN THE CARTON IS IN ERECTED CONDITION, SAID BLANK HAVING A SMOOTH OUTER LINER WHICH PROVIDES A SMOOTH PRODUCT ENGAGING SURFACE IN THE INNER CELL FORMED BY SAID REMAINING FOUR PANELS, SAID CUSHION PANELS HAVING CENTRAL LONGITUDINAL CREASE LINES OF PREDETERMINED WIDTH FORMING GROOVES IN THE OPPOSED INNER FACES OF THE CUSHION PANELS FOR INSURING OUTWARD FLEXING OF SLIGHTLY OVERSIZE CUSHION PANELS AND WIDTH ELONGATION OF SLIGHTLY UNDERSIZE CUSHION PANELS, THE INLET ENDS OF SAID CREASE LINES FORMING A FUNNEL FOR CENTRALLY GUIDING A PRODUCT INTO THE CARTON. 